SUBARU LEGACY 1997 Service Repair Manual

1. Engine Coolant Pump
G2M0201

1Engine coolant pump ASSY


2Gasket


3Heater hose


4Thermostat


5Gasket


6Thermostat case
Tightening torque: N⋅m (kg-m, ft-lb)
T1: First 10+4
0(1.0+0.4
0, 7.2+2.9
0)
Second 10+4
0(1.0+0.4
0, 7.2+2.9
0)
T2: 6.4±0.5 (0.65±0.05, 4.7±0.4)
4
2-5COMPONENT PARTS
1. Engine Coolant Pump

2. Radiator and Radiator Fan
B2M0300A

1Radiator lower cushion


2Radiator


3O-ring


4Air vent plug


5Radiator upper cushion


6Radiator upper bracket


7Clamp


8Radiator inlet hose


9Engine coolant reservoir tank cap


10Over flow hose


11Engine coolant reservoir tank


12Shroud


13Radiator main fan motor ASSY


14Radiator outlet hose

15Radiator drain pipe


16Gasket


17Radiator drain plug


18ATF hose clamp


19ATF inlet hose A


20ATF outlet hose A


21ATF pipe


22ATF outlet hose B


23ATF inlet hose B
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 6.9±1.5 (0.7±0.15, 5.1±1.1)
T2: 12±3 (1.2±0.3, 8.7±2.2)
5
2-5COMPONENT PARTS
2. Radiator and Radiator Fan

3. Engine Coolant Pipe
G2M0203

1Engine coolant temperature sensor


2Engine coolant temperature gauge


3Engine coolant pipe


4O-ring


5By-pass hose
Tightening torque: N⋅m (kg-m, ft-lb)
T: 6.4±0.5 (0.65±0.05, 4.7±0.4)
6
2-5COMPONENT PARTS
3. Engine Coolant Pipe

1. On-Car Service
A: DRAINING OF ENGINE COOLANT
1) Lift-up the vehicle.
B2M0133A
2) Fit vinyl tube to drain pipe.
B2M0015A
3) Loosen drain cock to drain engine coolant into con-
tainer.
NOTE:
Remove radiator cap so that engine coolant will drain
faster.
B2M0301
B: FILLING OF ENGINE COOLANT
1) Remove air vent plug from radiator.
B2M0135
2) Fill engine coolant into radiator up to filler neck position.
7
2-5SERVICE PROCEDURE
1. On-Car Service

B2M0140
3) Fill engine coolant into reservoir tank up to upper level.
4) Attach radiator cap and reservoir tank cap properly.
5) Install air vent plug.
6) Warm-up engine completely for more than five minutes
at 2,000 to 3,000 rpm.
7) Stop engine and wait until temperature drops to a safe
level.
8) If engine coolant level drops in radiator, add engine
coolant to filler neck position.
9) If engine coolant level drops from upper level of reser-
voir tank, add engine coolant to upper level.
10) Attach radiator cap and reservoir tank cap properly.
B2M0136
C: CHECKING OF COOLING SYSTEM
1) Remove radiator cap, top off radiator, and attach tester
to radiator in place of cap.
2) Apply a pressure of 157 kPa (1.6 kg/cm
2, 23 psi) to
radiator to check if:
(1) Engine coolant leaks at/around radiator.
(2) Engine coolant leaks at/around hoses or connec-
tions.
CAUTION:
Engine should be off.
Wipe engine coolant from check points in advance.
Be careful to prevent engine coolant from spurting
out when removing tester.
Be careful also not to deform filler neck of radiator
when installing or removing tester.
8
2-5SERVICE PROCEDURE
1. On-Car Service

G6M0095
2. Engine Coolant Pump
A: REMOVAL
1) Open engine hood.
2) Disconnect ground cable from the battery.
B2M0015A
3) Drain engine coolant completely.
<Ref. to 2-5 [W1A0].>
B2M0137
4) Disconnect radiator outlet hose from engine coolant
pump.
B2M0323
5) Remove radiator fan motor assembly.
<Ref. to 2-5 [W6A0].>
G2M0286
6) Remove V-belt(s).
<Ref. to 1-5 [01B0].>
9
2-5SERVICE PROCEDURE
2. Engine Coolant Pump

B2M0302
7) Remove timing belt.
<Ref. to 1-5 [02A0].>
B2M0303
8) Remove belt tension adjuster.
G2M0417
9) Remove camshaft position sensor.
<Ref. to 2-7 [W10A0].>
G2M0207
10) Remove left side camshaft pulley by using ST.
ST 499207100 CAMSHAFT SPROCKET WRENCH
G2M0208
11) Remove left side rear timing belt cover.
10
2-5SERVICE PROCEDURE
2. Engine Coolant Pump

G2M0210
12) Remove tensioner bracket.
13) Disconnect heater hose from engine coolant pump.
14) Remove engine coolant pump.
B: INSPECTION
1) Check engine coolant pump bearing for smooth rota-
tion.
2) Check engine coolant pump pulley for abnormalities.
G2M0211
3) Using a dial gauge, measure impeller runout in thrust
direction while rotating the pulley.
“Thrust”runout limit:
0.5 mm (0.020 in)
G2M0212
4) Check clearance between impeller and pump case.
Clearance between impeller and pump case:
Standard
0.5—0.7 mm (0.020—0.028 in)
Limit
1.0 mm (0.039 in)
5) After engine coolant pump installation, check pulley
shaft for engine coolant leaks. If leaks are noted, replace
engine coolant pump assembly.
11
2-5SERVICE PROCEDURE
2. Engine Coolant Pump

G2M0213
C: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in fig-
ure.
Tightening torque:
10
+4
0N⋅m (1.0+0.4
0kg-m, 7.2+2.9
0ft-lb)
G2M0214
3. Thermostat
A: REMOVAL AND INSTALLATION
1) Drain engine coolant.
Set container under the vehicle, and remove drain cock
from radiator.
2) Disconnect radiator outlet hose from thermostat cover.
3) Remove thermostat cover and gasket, and pull out the
thermostat.
G2M0227
4) Install the thermostat in the intake manifold, and install
the thermostat cover together with a gasket.
CAUTION:
When reinstalling the thermostat, use a new gasket.
The thermostat must be installed with the jiggle pin
upward.
In this time, set the jiggle pin of thermostat for front
side.
G2M0215
B: INSPECTION
Replace the thermostat if the valve does not close com-
pletely at an ambient temperature or if the following test
shows unsatisfactory results.
Immerse the thermostat and a thermometer in water. Raise
water temperature gradually, and measure the temperature
and valve lift when the valve begins to open and when the
valve is fully opened. During the test, agitate the water for
even temperature distribution. The measurement should
be to the specification.
Starts to open:
76.0—80.0°C (169—176°F)
Fully opens:
91°C (196°F)
12
2-5SERVICE PROCEDURE
2. Engine Coolant Pump - 3. Thermostat

G2M0213
C: INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Replace gasket with a new one.
When installing engine coolant pump, tighten bolts
in two stages in numerical sequence as shown in fig-
ure.
Tightening torque:
10
+4
0N⋅m (1.0+0.4
0kg-m, 7.2+2.9
0ft-lb)
G2M0214
3. Thermostat
A: REMOVAL AND INSTALLATION
1) Drain engine coolant.
Set container under the vehicle, and remove drain cock
from radiator.
2) Disconnect radiator outlet hose from thermostat cover.
3) Remove thermostat cover and gasket, and pull out the
thermostat.
G2M0227
4) Install the thermostat in the intake manifold, and install
the thermostat cover together with a gasket.
CAUTION:
When reinstalling the thermostat, use a new gasket.
The thermostat must be installed with the jiggle pin
upward.
In this time, set the jiggle pin of thermostat for front
side.
G2M0215
B: INSPECTION
Replace the thermostat if the valve does not close com-
pletely at an ambient temperature or if the following test
shows unsatisfactory results.
Immerse the thermostat and a thermometer in water. Raise
water temperature gradually, and measure the temperature
and valve lift when the valve begins to open and when the
valve is fully opened. During the test, agitate the water for
even temperature distribution. The measurement should
be to the specification.
Starts to open:
76.0—80.0°C (169—176°F)
Fully opens:
91°C (196°F)
12
2-5SERVICE PROCEDURE
2. Engine Coolant Pump - 3. Thermostat